BENDIX BRSM0890 User manual

For the most current information, visit the Roadranger web site at www.roadranger.com

16.5" Series S-Cam Cast

XTRALIFE

TM 

P-Series

XTRALIFE II

TM

Dana

®

Spicer

®

Brakes

Service Manual BRSM-0890 October 1997

TABLE OF CONTENTS

i

GENUINE SPICER SERVICE PARTS

Should a brake assembly require replacement component parts, it is recommended that Spicer

Brake Service Parts be used. Spicer Brake Service Parts are manufactured under the same rigid

specification as are original equipment brake components. This assures the customer who uses

genuine Spicer service parts, maximum reliability for a Spicer Brake assembly. They may be

obtained through your vehicle manufacturer. The use of non-original Spicer service parts may

cause premature compontent failure and may void the warranty.

The items included in this book are currently being offered as service parts at the time of

printing. The part numbers and illustrations are provided specifically for reference purposes

only. Therefore, Spicer reserves the right to update this manual without notice or liability.

Identification ..................................................................... 2

Brake Components (Standard/Xtralife) ...................... 3

Brake Components (Cast Series).................................. 4

Brake Components (XL II Series).................................. 5

Brake Components (“P” Series) .................................... 6

General Precautions ......................................................... 7

Preventative Maintenance............................................... 9

Brake Disassembly ............................................................ 11

Inspection of Parts ........................................................... 12

Brake Assembly ................................................................. 15

Trouble Shooting Charts ................................................. 18

Reline Procedure ............................................................... 21

97 170

IDENTIFICATION

2

The brake assembly may be identified by a tag which is

located on the camshaft bracket cylinder, near the

grease fitting.

The mylar brake assembly tag contains the following:

Dana assembly number, bar coded customer assembly

number, and a numeric customer assembly number.

DAY OF YEARMODEL YEAR

JULIAN DATE CODE

Two other markings that may be used to identify a

Spicer Brake assembly are located on the assembly's

components. "Spicer" will be cast into the spider

assembly just above the anchor pins. Also, the inside of

the chamber bracket arm contains the following stamped

part information: "Spicer", julian date code, and the part

number.

Brake Assembly Tag

CUSTOMER

ASSEMBLY

NUMBER

CUSTOMER

BAR CODE

NUMBER

165 WD 000 0

MODEL IDENTIFICATION NUMBERING SYSTEM

Alphabetical Code

(i.e., WD = Brake Assembly)

Model (165 = 16.5" Brake)

(150 = 15" Brake)

DANA

ASSEMBLY NUMBER

Sequential Assembly

Numbers

Camshaft Bracket

CHAMBER

BRACKET ARM

STAMPED PART

INFORMATION

BRAKE ASSEMBLY TAG

Camshaft

STAMPED PART

INFORMATION

(IN ONE OF THESE AREAS)

"SPICER"

Spider

BUILD DATE

(APR 1997 AND LATER)

BRAKE COMPONENTS

STANDARD/ XTRALIFE 16.5"

3

Retaining Ring

Camshaft Adjusting

Washers (Shims)

Grease Fitting

Air Chamber

Bracket Assembly

Grease Seal

Steel Spacer

Camshaft Bushing

Bracket Mounting Bolt

(70 - 80 Lb-Ft)

(95 - 108 N-m)

Lock Washer

Grease Seal

Steel Spacer Plate

Camshaft

Shoe Return Spring

Cam Roller

Spider

Lining

Shoe and Lining

Assembly

Brake Lining

Rivet

Lock Washer

Dustshield Mounting Bolt

3/8 in. - 16

(20 - 28 Lb-Ft)

(27 - 38 N-m)

Return Spring Pin

Retainer Springs

BRAKE COMPONENTS

16.5" CAST SHOE SERIES

Retaining Ring

Camshaft Adjusting

Washers (Shims)

Grease Fitting

Air Chamber

Bracket Assembly

Grease Seal

Steel Spacer

Camshaft Bushing

Bracket Mounting Bolt

(70 - 80 Lb-Ft)

(95 - 108 N-m)

Lock Washer

Grease Seal

Lock Washer

Dust Shield Half

Spider

Steel Spacer Plate

Camshaft

Anchor Pin Bushing

Grease Fitting

Brake Lining Nut

(15-17 Lb-Ft)

(20-23 N-m)

Shoe Return Spring

Cam Roller

Anchor Pin

Retainer Clip

Brake Lining

Bronze Bushing

Anchor Pin

Retainer Clip

Lining

Shoe and Lining

Assembly

Brake Lining

Bolt

4

Dustshield Mounting Bolt

3/8 in. - 16

(20 - 28 Lb-Ft)

(27 - 38 N-m)

Washer

Lock Washer

BRAKE COMPONENTS

16.5" XL II SERIES BRAKE

Retaining Ring

Camshaft Adjusting Washer

Steel Spacer

Grease Seal

Camshaft Bushing

Camshaft Bracket

Camshaft Bushing

Grease Seal

Spider

Steel Spacer Plate

Camshaft

Shoe and

Lining Assembly

Cam Roller

Shoe Retainer Spring

Shoe Return Spring

Anchor Pin

Anchor Pin Bushing

Return Spring Pin

Lining

Dust Shield (Half)

Bracket Mounting Bolt

(70 - 80 Lb-Ft)

(95 - 108 N-m)

Lock Washer

Dustshield Mounting Bolt

3/8 in. - 16

(20 - 28 Lb-Ft)

(27 - 38 N-m)

Grease Fitting

Lock Washer

Brake Lining Rivet

Cam Roller

Retainer Clip

5

BRAKE COMPONENTS

16.5" P SERIES BRAKE

Retainer Ring

Camshaft Adjusting Washer

Steel Spacer

Grease Seal

Camshaft Bushing

Camshaft Bracket

Camshaft Bushing

Grease Seal

Spider

Steel Spacer Plate

Camshaft

Cam Roller

Shoe Return Spring

Anchor Pin

Anchor Pin Bushing

Return Spring Pin

Lining

Dust Shield (Half)

Bracket Mounting Bolt

(70 - 80 Lb-Ft)

(95 - 108 N-m)

Lock Washer

Dustshield Mounting Bolt

3/8 in. - 16

(20 - 28 Lb-Ft)

(27 - 38 N-m)

Grease Fitting

Lock Washer

Brake Lining Rivet

Cam Roller

Retainer Clip

6

Washer

Snap Ring

7

GENERAL PRECAUTIONS

All Spicer original equipment or service parts for

steering and drive axle brakes are manufactured using

non-asbestos brake lining. It is recommended that

original Spicer service parts be used when brake mainte-

nance is necessary.

SAFETY PRECAUTIONS

Proper service and repair of vehicle components is

important to the safe and reliable operation of all motor

vehicles. This applies particularly to brakes such as the

ones described in this manual. The procedures recom-

mended and described in this manual are tested,

effective methods for performing service operation.

Follow each procedure closely, making use of both the

text and pictures. Some of these service procedures

show the use of certain tools designed especially for the

operation being performed. It is not mandatory that

these tools be used; they are shown only as preferred

means of performing the operation. It is not practical to

anticipate and advise the service trade of all possible

alternate service methods, and of all possible hazardous

consequences that could result from any particular

method. Accordingly, anyone who uses a service

procedure or tool different than shown must insure that

their safety, and that the vehicle’s safety will not be

jeopardized by the service method selected.

CA CA

CA

UTION:UTION:

UTION:

When wWhen w

When w

orking on or arorking on or ar

orking on or ar

ound airound air

ound air

brbr

br

akak

ak

e se s

e s

yy

y

stst

st

ems and componentems and component

ems and component

s, the follos, the follo

s, the follo

wingwing

wing

prpr

pr

ecautions should be observecautions should be observ

ecautions should be observ

ed:ed:

ed:

1.1.

1. Always block vehicle wheels. Stop engine when

working under a vehicle. Depleting vehicle air

system pressure may cause vehicle to roll. Keep

hands away from chamber push rods and slack

adjusters; they may automatically apply as system

pressure drops.

2.2.

2. Never connect or disconnect a hose or line con-

taining air pressure. It may whip as air escapes.

IMPORIMPOR

IMPOR

TT

T

ANTANT

ANT

READ THIS SECTION BEFORE STREAD THIS SECTION BEFORE ST

READ THIS SECTION BEFORE ST

ARAR

AR

TINGTING

TING

ANY SERANY SER

ANY SER

VICE PROCEDURESVICE PROCEDURES

VICE PROCEDURES

Never remove a component or pipe plug unless you

are certain all system pressure has been depleted.

3.3.

3. Never exceed recommended air pressure and always

wear safety glasses when working with air pressure.

Never look into air jets or direct them at anyone.

4.4.

4. Never attempt to disassemble a component until

you have read and understand recommended

procedures. Some components contain powerful

springs and injury can result if not properly

disassembled. Use only proper tools and observe

all precautions pertaining to use of those tools.

5.5.

5. Use only genuine Spicer replacement parts and

components.

A. A.

A. Only components, devices, mounting and

attaching hardware specifically designed for use

in air brake systems should be used.

B. B.

B. Replacement hardware, tubing, hose, fittings, etc.

should be of equivalent size, type, length and

strength as the original equipment.

C. C.

C. Make certain that when replacing tubing or hose,

all supports, clamps or suspending devices that

were originally installed by the vehicle manufac-

turer are reinstalled.

6.6.

6. Devices with stripped threads or damaged parts

should be replaced. Repairs requiring machining

should not be attempted.

CAUTION

BREATHING BRAKE DUST MAY BE HAZARDOUS TO YOUR HEALTH AND

MAY CAUSE SERIOUS RESPIRATORY OR OTHER BODILY HARM.

FOLLOW 0.S.H.A. STANDARDS FOR PROPER PROTECTIVE DEVICES TO BE USED

WHEN WORKING WITH BRAKE MATERIALS.

BRAKE LININGS CONTAIN NON-ASBESTOS FIBERS

AVOID CREATING DUST

DO NOT REMOVE BRAKE DRUM WITHOUT PROPER PROTECTIVE EQUIPMENT.

DO NOT WORK ON LININGS WITHOUT PROPER PROTECTIVE EQUIPMENT.

DO NOT REPLACE LININGS WITHOUT PROPER PROTECTIVE EQUIPMENT.

DO NOT ATTEMPT TO SAND, GRIND, CHISEL, FILE, HAMMER OR ALTER BRAKE

LININGS IN ANY MANNER WITHOUT PROPER PROTECTIVE EQUIPMENT.

8

PREPARATION

1.1.

1. Park vehicle on a level surface and prevent

movement by means other than the brakes.

2.2.

2. If equipped with spring brakes, cage the spring on

all axles to be worked on.

3.3.

3. Raise the axle, to be worked on until the tires

clear the ground. Support axle with heavy duty

jack stands.

4. "Back-off " slack adjuster by turning adjusting nut

until the brake shoes are fully retracted.

CACA

CA

UTION: RUTION: R

UTION: R

ockwockw

ockw

ell Autell Aut

ell Aut

o Slacks ro Slacks r

o Slacks r

equirequir

equir

e the pae the pa

e the pa

wlwl

wl

aa

a

ssemblssembl

ssembl

y ty t

y t

o be ro be r

o be r

emoemo

emo

vv

v

ed befored befor

ed befor

e turning the adjuste turning the adjust

e turning the adjust

--

-

ing ning n

ing n

ut.ut.

ut.

WW

W

ARNING: NeARNING: Ne

ARNING: Ne

vv

v

er wer w

er w

ork under a vork under a v

ork under a v

ehicle supporehicle suppor

ehicle suppor

tt

t

eded

ed

onlonl

onl

y by b

y b

y a jack. Alwy a jack. Alw

y a jack. Alw

aa

a

yy

y

s use a jack sts use a jack st

s use a jack st

and.and.

and.

GENERAL PRECAUTIONS (CONTINUED)

5.5.

5. Remove wheels and drums using the procedures

specified in the vehicle maintenance manual.

WW

W

ARNING: The long tARNING: The long t

ARNING: The long t

erm effecterm effect

erm effect

s of es of e

s of e

xposurxposur

xposur

e te t

e t

o non-o non-

o non-

aa

a

sbesbe

sbe

stst

st

os haos ha

os ha

s nos no

s no

t been det been de

t been de

tt

t

ermined. Aermined. A

ermined. A

vv

v

oid croid cr

oid cr

eaea

ea

tingting

ting

dust when perdust when per

dust when per

forming service on brforming service on br

forming service on br

akak

ak

e ae a

e a

ssembliessemblie

ssemblie

s.s.

s.

ExEx

Ex

cece

ce

ssivssiv

ssiv

e ee e

e e

xposurxposur

xposur

e te t

e t

o bro br

o br

akak

ak

e dust mae dust ma

e dust ma

y cause ry cause r

y cause r

ee

e

spirspir

spir

a-a-

a-

tt

t

ory damage or oory damage or o

ory damage or o

ther bodilther bodil

ther bodil

y harm.y harm.

y harm.

Safety glasses should be worSafety glasses should be wor

Safety glasses should be wor

nn

n

at all times when assemblingat all times when assembling

at all times when assembling

or disassembling brakes.or disassembling brakes.

or disassembling brakes.

Standard Chamber Long Stroke Chamber

Rated Stroke Max Readjust Stroke Rated Stroke Max Readjust Stroke

12 1.75 1.38 2.00 1.50

16 2.25 1.75 2.50 2.00

20 2.25 1.75 2.50 2.00

24 2.25 1.75 2.50 2.00

30 2.50 2.00 2.75 2.25

36 3.00 2.25 - -

A schedule should be eA schedule should be e

A schedule should be e

stst

st

ablished for periodicablished for periodic

ablished for periodic

adjustment, inspection and lubricaadjustment, inspection and lubrica

adjustment, inspection and lubrica

tion. This sched-tion. This sched-

tion. This sched-

ule is deule is de

ule is de

tt

t

ermined frermined fr

ermined fr

om vom v

om v

ehicle oehicle o

ehicle o

wner/operwner/oper

wner/oper

aa

a

tt

t

oror

or

ss

s

ee

e

xperience and the txperience and the t

xperience and the t

ype of operype of oper

ype of oper

aa

a

tiontion

tion.

BRAKE DRUMS

Inspect for heat checks, grooves, hot spots, glazing,

cracks, and out of round. Drums which are glazed,

grooved, or have moderate heat checking may be

resurfaced and returned to service. The drum should

not be used if it exceeds the manufacturer’s recom-

mended maximum diameter stamped on the drum.

BRAKE ADJUSTMENT

Brakes should be adjusted whenever the air chamber

push rod stroke exceeds the maximum distance accord-

ing to the chart shown in

FF

F

igurigur

igur

e 2e 2

e 2. To determine if

brake adjustment is required measure the push rod

stroke with the brakes applied as shown in

FF

F

igurigur

igur

e 3e 3

e 3

onon

on

page 1page 1

page 1

0.0.

0.

PREVENTATIVE MAINTENANCE

CA CA

CA

UTION:UTION:

UTION:

Drums displaDrums displa

Drums displa

ying heaying hea

ying hea

t checks witht checks with

t checks with

a contina contin

a contin

uous length of four incheuous length of four inche

uous length of four inche

s or mors or mor

s or mor

e ande and

e and

ee

e

xtxt

xt

ends arends ar

ends ar

ound the edge of the drum should beound the edge of the drum should be

ound the edge of the drum should be

rr

r

eplaced. eplaced.

eplaced.

See FSee F

See F

igurigur

igur

e 1.e 1.

e 1.

FF

F

igurigur

igur

e 1e 1

e 1

FF

F

igurigur

igur

e 2e 2

e 2

Chamber Size

Type

RECOMMENED AIR BRAKE ACTUATOR SERVICE STROKE

Source: The Maintenance Council RP 635

9

10

PREVENTATIVE MAINTENANCE

AA

A

A.A.

A. Released Position

B. B.

B. Applied Postion

BB

B

MEASURING PUSH ROD STROKE

1.1.

1. Measure the distance between the air chamber

mounting face and the center of the clevis pin,

with brakes released.

2.2.

2. Make an 70-90 PSI application and hold it.

Measure the distance between the air chamber and

the mounting face and the center of the clevis pin.

3.3.

3. Subtract measurement A from measurement B. If

this measurement equals or exceeds the maximum

readjust stroke the brakes need to be adjusted.

See FSee F

See F

igurigur

igur

e 3.e 3.

e 3.

4.4.

4. If adjustment is required, spin the wheel slowly and

adjust the slack adjuster just enough for wheel to

spin freely. Be sure to adjust brakes equally on

each axle.

5.5.

5. Apply and release brakes and observe slack

adjusters. Both slacks on each axle should respond

rapidly and in unison during application and

release.

6.6.

6. Drive vehicle at a low speed in a safe area and

check for brake effectiveness prior to putting back

in service.

F F

F

igurigur

igur

e 3e 3

e 3

BRAKE LUBRICTION

Lubricate the camshaft thru the grease fitting on the

camshaft bracket with the chassis lube specified by the

vehicle manufacturer. Lube once every six months or at

every chassis lubrication.

BRAKE RELINE

The life of the brake lining is dependent on many factors

such as the material of the lining, type of operation the

vehicle is used for, geographic terrain, maintenance

practice of the shop, and the driver of the vehicle. If

driving conditions require frequent braking, lining

replacement will be required more often.

FOR RIVET LINING

Reline when thickness of lining is 1/4 " at thinnest

point, or 1/16" above rivet head.

FOR CAST SHOES WITH BOLTED LININGS

Reline when lining is below wear indicator line or

thickness is .31" at the thinnest point or 1/16" above

bolt head.

BRAKE OVERHAUL

As often as necessary to maintain satisfactory brake

performance. When overhauling the brakes, provide equal

service to both the left and right side of an axle.

BRAKE DISASSEMBLY

CAST SHOE & "P" SERIES

1.1.

1. Insert sturdy lever between end of shoe and spider.

Pry shoe away from cam until cam rollers can be

removed. Repeat procedure for opposite shoe.

2.2.

2. Unhook shoe return spring by pushing shoes

together, allow tension on spring to be reduced.

3.3.

3. Discard shoe return spring and replace with new at

time of reassembly.

4.4.

4. Remove snap ring from anchor pin and push anchor

pin through.

NONO

NO

TE: TTE: T

TE: T

ap lightlap lightl

ap lightl

y with bry with br

y with br

aa

a

ss drift if anchor pin willss drift if anchor pin will

ss drift if anchor pin will

nono

no

t push out with fingert push out with finger

t push out with finger

..

.

5.5.

5. Remove brake shoe and place on floor. Repeat

procedure for opposite shoe.

STANDARD, XL, & XLII SERIES

1.1.

1. Insert sturdy lever between end of shoe and spider.

Pry shoe away from cam until cam rollers can be

removed. Repeat procedure for opposite shoe.

2.2.

2. Unhook shoe return spring by pushing shoes

together, allow tension on spring to be reduced.

3.3.

3. Discard shoe return spring and replace with new at

time of reassembly.

4a.4a.

4a.

SS

S

TT

T

ANDAND

AND

ARD & XLARD & XL

ARD & XL

Remove shoes by rotating the bottom shoe off the

anchor pin to release the tension on the two

retaining springs.

4b.4b.

4b.

XLII SERIESXLII SERIES

XLII SERIES

Remove snap ring from anchor pin and push anchor

pin through.

5.5.

5. Remove the two retaining springs and discard.

6.6.

6. Remove shoes from spider.

11

CAMSHAFT REMOVAL

1.1.

1. Before removing camshaft check to see if cam bushings

need replacement.

See F See F

See F

igurigur

igur

e 4 on Pe 4 on P

e 4 on P

age 1age 1

age 1

2.2.

2.

2.2.

2. Remove spacer from between slack adjuster and cam

shaft bracket.

3.3.

3. Grasp camshaft at the camshaft head and pull in the

outward direction to remove.

4.4.

4. Clean and inspect camshaft splines and head.

AIR CHAMBER/ CAMSHAFT BRACKET

ASSMEBLY REMOVAL

1.1.

1. Remove two nuts and washers that secure brake cham-

ber to camshaft bracket.

2.2.

2. Remove brake chamber and temporarily set it aside.

3.3.

3. Remove four bracket mounting bolts and lock washers.

4.4.

4. Remove bracket assembly from spider.

CA CA

CA

UTION: UTION:

UTION:

Do noDo no

Do no

t hammer on slack adjustt hammer on slack adjust

t hammer on slack adjust

er ter t

er t

oo

o

rr

r

emoemo

emo

vv

v

e. Serious damage te. Serious damage t

e. Serious damage t

o the slack adjusto the slack adjust

o the slack adjust

er and/er and/

er and/

or the camshaft splineor the camshaft spline

or the camshaft spline

s mas ma

s ma

y ry r

y r

ee

e

sult.sult.

sult.

SLACK ADJUSTER REMOVAL

1.1.

1. Disconnect clevis from slack adjuster arm by

removing the clevis pin or pins depending on type

of slack adjuster.

2.2.

2. Remove retaining ring and shims from splined end

of camshaft.

3.3.

3. Remove slack adjuster from the camshaft.

CA CA

CA

UTION: UTION:

UTION:

Do noDo no

Do no

t let le

t le

t the air chamber hang bt the air chamber hang b

t the air chamber hang b

yy

y

the air linethe air line

the air line

ss

s

AIR CHAMBER BRACKET ASSEMBLY

INSPECTION OF PARTS

SPIDER REMOVAL

1.1.

1. Mark the postion of the spider on the axle (L.H. or

R.H.) and the orientation on the axle flange by

making a reference mark on the spider and flange.

See FSee F

See F

igurigur

igur

e 4.e 4.

e 4.

2. 2.

2. Remove the spider to axle mounting bolts.

3. 3.

3. Remove spider.

DUST SHIELD REMOVAL

1.1.

1. Mark dust shields (upper left, lower right, etc-

prior to removal.

2.2.

2. Detach dust sheild by removing the six cap screws

using a 9/16" socket. Do not remove dust shield

unless there is apparent damage.

BRAKE DISASSEMBLY (CONTINUED)

FF

F

igurigur

igur

e 4e 4

e 4

1.1.

1. Check assembly for bent chamber bracket, broken

welds, cracks, and correct alignment.

2.2.

2. Inspect camshaft bushings for signs of wear.

Bearing surfaces should be smooth and free of any

pitting or fractures. Insert camshaft and measure

looseness up and down side to side at both ends

with a dial indicator. If more than .030” movement,

replace bushings and/or camshaft.

See FSee F

See F

igurigur

igur

e 5.e 5.

e 5.

NONO

NO

TE: If it is deTE: If it is de

TE: If it is de

tt

t

ermined thaermined tha

ermined tha

t a bushing rt a bushing r

t a bushing r

equirequir

equir

ee

e

ss

s

rr

r

eplacement, boeplacement, bo

eplacement, bo

th camshaft bushings and sealsth camshaft bushings and seals

th camshaft bushings and seals

should be rshould be r

should be r

eplaced. All CASeplaced. All CAS

eplaced. All CAS

T SHOE and P SERIEST SHOE and P SERIES

T SHOE and P SERIES

brbr

br

akak

ak

ee

e

s has ha

s ha

vv

v

e bre br

e br

onze cam bushings. The Sonze cam bushings. The S

onze cam bushings. The S

TT

T

ANDAND

AND

ARD,ARD,

ARD,

XL, and XLII SERIES brXL, and XLII SERIES br

XL, and XLII SERIES br

akak

ak

ee

e

s use ns use n

s use n

ylon bushings withylon bushings with

ylon bushings with

the brthe br

the br

onze bushing aonze bushing a

onze bushing a

s an ops an op

s an op

tion.tion.

tion.

CAMSHAFT

1.1.

1. Inspect camshaft spline and body for chips and

excessive deformation. Replace as necessary.

See FSee F

See F

igurigur

igur

e 6.e 6.

e 6.

2.2.

2. Inspect cam head for cracks, and its roller surfaces

for flat spots, brinneling, or ridges.

NONO

NO

TE: UnTE: Un

TE: Un

usual wusual w

usual w

ear paear pa

ear pa

tt

t

tt

t

erns which maerns which ma

erns which ma

y indicay indica

y indica

tt

t

e ane an

e an

outout

out

-of-squar-of-squar

-of-squar

e condition. Re condition. R

e condition. R

eplace damaged cam-eplace damaged cam-

eplace damaged cam-

shaftshaft

shaft

s.s.

s.

FF

F

igurigur

igur

e 5e 5

e 5

FF

F

igurigur

igur

e 6e 6

e 6

12

SHOES AND LINING

STANDARD, XL, XL II AND P SERIES

1.1.

1. Check shoes for bent shoe ribs, cracks in shoe

table welds or ribs, and elongated rivet holes.

Replace shoes if any of these conditions exist.

SeeSee

See

FF

F

igurigur

igur

e 9.e 9.

e 9.

2.2.

2. Measure the shoe span by loosely installing the

anchor pin and cam roller in the appropriate ends

of the shoe rib. If the distance from center of

anchor pin to center of cam roller exceeds 12.76

inches replace shoe.

3.3.

3. Check linings and replace when any of the following

conditions exist: See page 21 for reline procedure.

A.A.

A. Total lining thickness at thinnest point is 1/4"

or less, or 1/16" above the rivets.

B. B.

B. Linings are cracked or worn in an unusual or

odd pattern. For example: lining wear tapered

from side to side across the shoe table. Un

usual wear pattern can indicate damage to

foundation brake parts.

C. C.

C. Rivet holes are elongated in lining or shoes.

D. D.

D. Lining is oil soaked.

E. E.

E. Linings can be moved by hand because of loose

rivets.

13

SPIDER

1.1.

1. Inspect for cracked or broken surfaces on the

spider at the cam, anchor pins, and mounting bolt

holes. Replace any spider with visible damage. Do

not attempt to weld or repair the spiders.

SeeSee

See

FF

F

igurigur

igur

e 7e 7

e 7

..

.

XLII, P, & CAST SHOE SERIES

2a2a

2a. Check the inside diameter of the anchor pin hole

with bushing in place. Diameter must not exceed

1.282”. Replace bushing if necessary.

STANDARD & XL SERIES

2b.2b.

2b. The anchor pins are staked into the spider and are

not serviced separately. If the pins are loose or

grooved more than .030 inch, the spider assembly

must be replaced.

ROLLERS AND ANCHOR PINS, BUSHINGS

1.1.

1. Inspect rollers and anchor pins for flat spots,

galling, broken or cracked surfaces. Replace as

necessary.

See FSee F

See F

igurigur

igur

e 8.e 8.

e 8.

INSPECTION OF PARTS

FF

F

igurigur

igur

e 7e 7

e 7

FF

F

igurigur

igur

e 8e 8

e 8

FF

F

igurigur

igur

e 9e 9

e 9

INSPECTION OF PARTS (CONTINUED)

14

FF

F

igurigur

igur

e 1e 1

e 1

00

0

TRANSIT BRAKE (CAST SHOE ONLY) DRUM/

LINING CROSS REFERENCE CHART

1.1.

1. When installing new drums always use standard

thickness lining. If used drums are rebored care-

fully measure inside diameter (in several places) of

rebored drum.

LINING MAXIMUM THICKNESS (IN) DRUM DIA. (IN) AT RELINE

.867” (Standard Thickness)

.927” (1X Oversize)

.987” (Premium Thickness)

16.500”- New

16.620”

Over 16.620”

CA CA

CA

UTION:UTION:

UTION:

NeNe

Ne

vv

v

er shim brer shim br

er shim br

akak

ak

e linings. See pagee linings. See page

e linings. See page

22

2

1, R1, R

1, R

eline Preline Pr

eline Pr

ocedurocedur

ocedur

e, for more, for mor

e, for mor

e dee de

e de

tt

t

ail.ail.

ail.

2.2.

2. Refer to the chart below for proper oversized lining

required based on drum measurements.

SHOES AND LINING

CAST SHOE TYPE

1.1.

1. Check shoes for cracks and elongated bolt holes.

2.2.

2. Measure the shoe span by loosely installing the

anchor pin and cam roller in the appropriate ends

of the shoe rib. If the distance from center of

anchor pin to center of cam roller exceeds 12.76

inches replace shoe.

3.3.

3. Check linings, replace when any of the following

conditions exist.

A. Total lining thickness at thinnest point is .31” or

less than 1/16” above screw head. Also, if the

material is worn beyond the wear groove on the

side of the lining.

B.B.

B. Linings are cracked or worn in an unusual or

odd pattern. For example: lining wear tapered

from side to side across the shoe table. Un

usual wear pattern can indicate damage to

foundation brake parts.

C.C.

C. Screw holes are elongated.

D.D.

D. Lining is oil soaked.

E.E.

E. Lining can be moved by hand. (loose bolts)

CA CA

CA

UTION:UTION:

UTION:

Drums displaDrums displa

Drums displa

ying heaying hea

ying hea

t checks witht checks with

t checks with

a contina contin

a contin

uous length of four incheuous length of four inche

uous length of four inche

s or mors or mor

s or mor

e ande and

e and

ee

e

xtxt

xt

end arend ar

end ar

ound the edge of the drum should beound the edge of the drum should be

ound the edge of the drum should be

rr

r

eplaced. eplaced.

eplaced.

See FSee F

See F

igurigur

igur

e 1e 1

e 1

0.0.

0.

BRAKE DRUMS

1.1.

1. Inspect drums for cracks, heat checking, glazing,

grooving, severe out-of-round condition or bell

mouthing

mm

m

ust noust no

ust no

t et e

t e

xx

x

ceed .0ceed .0

ceed .0

22

2

5 T5 T

5 T

.I.R. (T.I.R. (T

.I.R. (T

oo

o

tt

t

alal

al

IndicaIndica

Indica

tt

t

or Ror R

or R

eading) eading)

eading) Replace any drums that are

cracked. The drum should not be used if it exceeds

the manufacturer’s recommended maximum

diameter stamped on the drum.

2.2.

2. Measure the drum I.D. to be sure the maximum limit

allowed (stamped on drum) has not been exceeded

due to wear or machining.

CAUTION: Maximum discard

diameter is 16.750”

CA CA

CA

UTION:UTION:

UTION: Left Hand and Right Hand does

not

establish which side of the vehicle the cam goes on. Left

and right are used to identify the two different types of

cams only.

2.2.

2. Place steel spacer plate over splined end and slide

next to cam head.

(See br(See br

(See br

akak

ak

e componente component

e component

s ons on

s on

pagepage

page

s 3-6)s 3-6)

s 3-6)

3.3.

3. Coat bushing, seals, journals and camshaft spline

with light film of chassis lube.

IMPORIMPOR

IMPOR

TT

T

ANTANT

ANT

: Do no: Do no

: Do no

t coat coa

t coa

t "S" cam head.t "S" cam head.

t "S" cam head.

4.4.

4. Carefully install camshaft through the chamber

bracket tube, from spider end. Cam must rotate

freely when turned by hand.

IMPORIMPOR

IMPOR

TT

T

ANTANT

ANT

: Be car: Be car

: Be car

eful noeful no

eful no

t tt t

t t

o damage the gro damage the gr

o damage the gr

eaea

ea

sese

se

seals.seals.

seals.

SPICER S-CAM BRAKE RETURN SPRINGS

Br Br

Br

akak

ak

e Seriee Serie

e Serie

ss

s

RR

R

ee

e

turn Springs P/N & Colorturn Springs P/N & Color

turn Springs P/N & Color

Standard 165WJ110 Dark Blue

XL & Cast Shoe 165WJ115 White

XLII 165WJ129 Light Blue

BRAKE ASSEMBLY

CA CA

CA

UTION:UTION:

UTION:

The lip of the grThe lip of the gr

The lip of the gr

eaea

ea

se seals mse seals m

se seals m

ust beust be

ust be

instinst

inst

alled corralled corr

alled corr

ectlectl

ectl

y ty t

y t

o pro pr

o pr

ee

e

vv

v

ent posssible damage. Theent posssible damage. The

ent posssible damage. The

lip of the seal thalip of the seal tha

lip of the seal tha

t is instt is inst

t is inst

alled in the spider end malled in the spider end m

alled in the spider end m

ustust

ust

entent

ent

er the opening firer the opening fir

er the opening fir

st. The lip of the seal thast. The lip of the seal tha

st. The lip of the seal tha

t ist is

t is

instinst

inst

alled in the oppositalled in the opposit

alled in the opposit

e end of the cam tube me end of the cam tube m

e end of the cam tube m

ustust

ust

entent

ent

er laer la

er la

st. st.

st.

See FSee F

See F

igurigur

igur

e 1e 1

e 1

11

1

. Inst. Inst

. Inst

all the chamberall the chamber

all the chamber

brbr

br

ackack

ack

ee

e

t and the cam tube at and the cam tube a

t and the cam tube a

ssemblssembl

ssembl

y onty ont

y ont

o the spidero the spider

o the spider

using four cap scrusing four cap scr

using four cap scr

ee

e

ww

w

s and lockws and lockw

s and lockw

aa

a

shersher

sher

s. Ts. T

s. T

oror

or

que tque t

que t

oo

o

77

7

0-80-8

0-8

0 Lb-Ft.0 Lb-Ft.

0 Lb-Ft.

If removed, reinstall the dust shields. Tighten the six cap

screws and lockwashers to 20-28 Lb-Ft of torque.

SPIDER

1.1.

1. Use a wire brush to remove heavy contamination

from the spider mounting flange, knuckle, spider,

brake drum exterior, and chamber mounting

bracket.

2.2.

2. Install the spider and chamber bracket assembly

onto the axle flange. Be sure spider is properly

oriented, as noted during disassembly. Tighten

mounting fastener to manufacturer's specifications.

CAMSHAFT

1.1.

1. Prior to reassembly, verify the part number is

correct there are L.H. and R.H. camshafts and they

can not be interchanged.

See FSee F

See F

igurigur

igur

e 1e 1

e 1

2.2.

2.

Seal Installation

CHAMBER BRACKET ASSEMBLY

15

Lip SealLip Seal

Lip Seal

SpiderSpider

Spider

AA

A

ctuactua

ctua

tt

t

or Bror Br

or Br

ackack

ack

ee

e

tt

t

and Cam Tand Cam T

and Cam T

ubeube

ube

Slack ASlack A

Slack A

djustdjust

djust

er Ender End

er End

NONO

NO

TE: BoTE: Bo

TE: Bo

th lip seals point the sameth lip seals point the same

th lip seals point the same

dirdir

dir

ection, lip tection, lip t

ection, lip t

oo

o

ww

w

arar

ar

d the slack adjustd the slack adjust

d the slack adjust

erer

er

Lip SealLip Seal

Lip Seal

End CamEnd Cam

End Cam

FF

F

igurigur

igur

e 1e 1

e 1

11

1

Right Hand CamRight Hand Cam

Right Hand Cam

Left Hand CamLeft Hand Cam

Left Hand Cam

FF

F

igurigur

igur

e 1e 1

e 1

22

2

BRAKE SHOE ASSEMBLY

STANDARD, XL & XL II SERIES

1.1.

1. Install new return spring pins:

A. StA. St

A. St

andarandar

andar

d Seried Serie

d Serie

ss

s- Wireform pin installed in shoe

ribs with mallet.

B. XL SerieB. XL Serie

B. XL Serie

ss

s- 2 piece kit assembly consisting of

inner pin and outer pin.

2.2.

2. Apply a thin film of Lubriplate 630-A grease or its

equivalent to the anchor pin.

3.3.

3. Install new brake retaining springs in the anchor

end of shoes. Place the top shoe onto the spider

by engaging the open slots on the end with the

retaining springs onto the anchor pin. Place

opposite end of the shoe against the S-cam. Swing

the lower shoe, with springs attached, back until

slots in the shoe engage the anchor pin. Rotate the

shoe toward the S-cam. Lower shoe may require

support while completing assembly.

4a.4a.

4a.

StSt

St

andarandar

andar

d Seried Serie

d Serie

ss

s- Utilize leg on shoe return spring

to aid in assembly. Place the one hook of the brake

shoe return spring onto the return spring pin.

Hold shoes firmly against the S-cam. Push the

other hook of the brake shoe return spring over the

opposite return spring pin until it snaps in place.

4b.4b.

4b.

XL/XL II SerieXL/XL II Serie

XL/XL II Serie

ss

s- place the one hook of the brake

shoe return spring onto the return spring pin

located between the shoe ribs. Hold both shoes

against the S-cam head. Push the other hook of

the return spring over the opposite shoe spring pin

until it snaps in place.

5.5.

5. Apply a thin film of Lubriplate 630-A grease or its

equivalent to the cam roller journal, and the roller

side only. Do not put grease on the end of the

roller which contacts the cam head.

6.6.

6. Insert sturdy lever between end of shoe and the

return spring pin.

See FSee F

See F

igurigur

igur

e 1e 1

e 1

33

3. Pry away from

the cam until cam rollers can be installed between

BRAKE ASSEMBLY (CONTINUED)

the S-cam and the slots in the end of the brake

shoe. Make sure the cam rollers are in the lowest

position on the cam. Repeat procedure for oppo-

site side.

CAST SHOE SERIES

1.1.

1. Apply a thin film of Lubriplate 630-A grease or its

equivalent to the anchor pin.

2.2.

2. Place snap ring on anchor pin end with grease

fitting. Place thin spacer onto anchor pin.

3.3.

3. Align anchor pin end of cast shoe with spider bore.

4.4.

4. Install anchor pin through backside of shoe and

spider. Repeat procedure for opposite shoe.

5.5.

5. Place thin spacer onto opposite side of anchor pins

and install snap rings.

6.6.

6. Hook shoe return spring by pushing shoes to-

gether. The cast shoe does not have a separate

return spring pin. The spring hook-up feature is

designed into the shoe casting.

77

7

..

. Insert sturdy lever between end of shoe and spider.

Pry shoe away from cam until cam rollers can be

installed. Repeat procedure for opposite side.

SeeSee

See

FF

F

igurigur

igur

e 1e 1

e 1

3.3.

3.

16

FF

F

igurigur

igur

e 1e 1

e 1

33

3

BRAKE ASSEMBLY (CONTINUED)

17

FF

F

igurigur

igur

e 1e 1

e 1

44

4

“P” SERIES

11

1. Install new return spring pins.

See FSee F

See F

igurigur

igur

e 1e 1

e 1

4.4.

4.

2.2.

2. Align lower end of fabricated shoe with spider bore.

3.3.

3. Place snap ring on anchor pin end with grease

fitting. Place thin spacer onto anchor pin.

4.4.

4. Install anchor pin through backside of shoe and

spider.

5.5.

5. Apply a thin film of Lubriplate 630-A grease or its

equivalent to the anchor pin.

6.6.

6. Place thin spacer onto opposite side of anchor pin

and install snap ring.

77

7

..

. Hook shoe return spring by pushing shoes to-

gether.

8.8.

8. Insert sturdy lever between end of shoe and spider.

Pry shoe away from cam until cam rollers can be

installed. Repeat procedure for opposite side.

SLACK ADJUSTER ASSEMBLY

1.1.

1. Reinstall thick camshaft flatwasher.

2.2.

2. Install new slack adjuster, shims, and a new snap

ring (In that sequence) into the splined end of the

camshaft.

3.3.

3. Adjust camshaft end play of the camshaft to

between .005" and .045" by using the appropriate

number of shims. Make sure the snap ring is seated

into the groove at the end of the splined camshaft.

BRAKE LUBRICATION

1.1.

1. Lubricate the camshaft bushings by filling the

camshaft tube with lube through the zerk fitting

provided. Fill until grease is forced out in the area

of the slack adjuster. Grease should not appear at

the cam head end. If it does, the seal has not been

properly installed, or the old seals should be

replaced.

2.2.

2. Reinstall brake drums and wheels. Torque and

adjust wheel bearings to manufacturer’s specifica-

tions.

NONO

NO

TE: Due tTE: Due t

TE: Due t

o the mano the man

o the man

y combinay combina

y combina

tions of slacktions of slack

tions of slack

adjustadjust

adjust

erer

er

s and brs and br

s and br

akak

ak

e chambere chamber

e chamber

s, follos, follo

s, follo

w vw v

w v

ehicleehicle

ehicle

manman

man

ufacturufactur

ufactur

er’er’

er’

s specificas specifica

s specifica

tions and prtions and pr

tions and pr

ocedurocedur

ocedur

ee

e

s fors for

s for

aa

a

ssemblssembl

ssembl

y and final adjustment.y and final adjustment.

y and final adjustment.

3.3.

3. Spin the wheel slowly and adjust the slack adjuster

until wheel will no longer turn. Back off slack

adjuster just enough for wheel to spin freely. Be

sure to adjust brakes equally on each axle.

4.4.

4. Apply the release brakes and observe slack adjust-

ers. Both slacks on each axle should respond

rapidly and in unison during application and

release.

5.5.

5. Drive vehicle at a low speed in a safe area and

check for brake effectiveness prior to putting back

in service.

4.4.

4. Grabbing or pulling.

A.A.

A. Grease, oil, or dirt on linings.

B.B.

B. Glazed linings.

C.C.

C. Brake linings not a balanced set,

different friction codes, or lining brand.

D.D.

D. Loose or broken linings.

E.E.

E. Brake drum out-of-round.

FF

F

..

. Defective brake drum.

G.G.

G. Clevis pin or camshaft binding at one

or more wheels.

H.H.

H. Defective slack adjuster.

I.I.

I. Uneven brake adjustment (side to side).

J.J.

J. Broken or bent parts.

K.K.

K. Loose spider or drum mounting bolts.

L.L.

L. Different air chamber size or slack

adjuster length (side to side).

A.A.

A. Replace lining.

B.B.

B. Deglaze lining or replace.

C.C.

C. Replace linings.

D.D.

D. Replace linings.

E.E.

E. Turn, per manufacturer's specifications.

FF

F

..

. Replace part.

G.G.

G. Clean and lubricate.

H.H.

H. Replace part.

I.I.

I. Adjust brakes.

J.J.

J. Replace part.

K.K.

K. Inspect and replace as necessary.

L.L.

L. Use same size and type both ends of

the axle.

18

FOUNDATION BRAKE TROUBLESHOOTING CHART

1.1.

1. Degraded brake

performance.

SYMPTOM CAUSE REMEDY

A.A.

A. Too much push rod free travel.

B.B.

B. Severely glazed or worn out linings.

C.C.

C. Grease or oil on linings.

D.D.

D. Worn, seared, heat checked, cracked

drums.

E.E.

E. Push rod length too long.

FF

F

..

. Air chamber in wrong position.

G.G.

G. Broken or bent parts.

H.H.

H. Flat spots on cam or rollers.

2.2.

2. Slow brake

application.

A.A.

A. Adjust brake.

B.B.

B. Deglaze linings or replace.

C.C.

C. Replace linings.

D.D.

D. Replace part.

E.E.

E. Adjust clevice, shorten push rod length

FF

F

..

. Reposition.

G.G.

G. Replace part.

H.H.

H. Replace flat-spotted parts.

A.A.

A. Cam shaft bushings binding.

A.A.

A. Clean and lubricate. Check for seal

leakage.

3.3.

3. Slow brake release.

A.A.

A. Binding cam shaft and bushing.

B.B.

B. Weak or broken shoe return

spring.

C.C.

C. Flat spotted cam or rollers.

A.A.

A. Clean and lubricate.

B.B.

B. Replace part.

C.C.

C. Replace flat-spotted parts.

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BENDIX BRSM0890 User manual

BENDIX BRSM0890 User manual

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